New Life for a Villager

Joined
Dec 10, 2005
Messages
3,410
I bought a 21" Chitlangi villager awhile ago and took it to Danny's shuriken seminar. Joe(Aardvark) and Norm(Svashtar) both mentioned that the horn handle would be beautiful if polished since it had streaks of gray throughout it. Since I can't polish my shoes without ruining them, Joe volunteered to polish it for me. When I got it back a short time later it was absolutely stunning. Here's some pics.

Thanks Joe!!

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Very nice! A villager blade with a polished horn looks great.

So, what does one do to polish horn?
 
So pretty. I am such a sucker for Chitlangis, especially in that length; the proportions are just so sweet.
 
I just got the Chitlangi from Aug 24 and am amazed by its heft. I have never handled one before, and didn't expect a 1/2" thick spine! I sort of overlooked the '37 Oz' part of the description, I guess. It's totally unlike any other khukri in my meager collection. The other cool thing is that the tools are full size -not little miniatures. The karda is 7" - with a 3 3/34" blade. Very usable, and sharp.
 
That Aardvark...he's a polishing rascal.:D


Other than that, not a bad guy.
 
So, what does one do to polish horn?
Simple work, if you have a bench grinder set up with a buffing wheel.

Before you do any sanding, put on some breathing protection. Horn dust is said to be bad for you.

Also before sanding, I put painter's tape around the bolster to avoid having to polish it out afterwards, should I accidentally hit the metal with the sandpaper.

Sand off any imperfections, if necessary. I usually start with 150, then 180, 220, stop with something that 3M calls 'Ultrafine'.

If there are serious flaws in the horn, you might have to start with a coarser grit.

You can always skip the sanding and go directly to the wheel, if you think it'll polish up nice without it. You can always go back if you find you're wrong.

Clean off any dust/powder from the handle.

I load the buffing wheel with tripoli compound and just keep going over the handle until I'm satisfied with the result. Rub it clean of compound with a soft cloth every once in a while, to see how it's progressing. Keep buffing until you're tired of doing it, you have the look you want, or dinner's ready.

Clean all the compound off the handle. For the grooves/checkering, I used an old toothbrush. This also has the effect of polishing the bottoms of them a little.

I put a coat or 2 of floor wax on the horn (Johnson's) when I'm done. Provides a really solid grip, especially when the hand gets a little sweaty.

Ted, she was a beauty to begin with. I just removed some of the pancake makeup and dabbed on a little lipstick. Thanks for letting me do it. It was fun.

Kis...you didn't give me a lot to work with there, so I'll just pass.
 
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